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Old 05-05-2009, 04:28 PM   #1
sakurama OP
on an endless build
 
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Joined: Oct 2004
Location: NYC & PDX
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My 950 Refresh or Mission Creep...

NOTE: So instead of starting a new thread every time I rebuild my bike or make some sort of change I've decided to just keep updating this one. It keeps it all more contained but also makes it a bit long. It is essentially a diary of my 950 Adventure and the changes I've made along the way.

- First teardown to the frame - 12
- Reassembly after powdercoat - 29-52
- New Brembo front master cylinder -post 60-74
- Beginning of second rebuild with 990 "Flanny Killer" engine - post 104
- Port comparison between 950 and 990 - post 130
- EFI timing gear install and 950 post mortum - post 149
- factory host crimp tool and second fan - post 159
- FCR inlet spigot tapering and TPS bracket - post 173
- beginning of exhaust fabrication - post 185
- screwing up exhaust flanges and subsequent welding - post 193
- exhaust spring anchor making tool - post 197
- stripping and prepping bodywork for paint - post 211
- fabrication of "X-crossover" - post 228
- first welding success - post 259
- resealing newly rebuilt wheels and exhaust layout - post 278
- more exhaust layout and tacking - 289 and 297
- final exhaust tacking - 332
- final welding of exhaust - 342
- fitting and first (disappointing) dyno runs - 352
- beginning of the bellmouth project - 433, 445, 452
- new exhaust mid pipes - 462
- first ride with the new pipe and the stock FCR's - 492
- first dyno test of custom billet velocity stacks for the FCR - 502
- the choke conundrum - can it be added to the FCR? - 596-?
- yes, we finally create a choke for the FCR - 655
- dyno testing the 41 FCR against the 39 -
- exploring the idea of a big bore kit for the 950/990
- the beginning of the two wheel drive Christini conversion - 771
- first test of the 2WD - 1027
- video of the worlds first two wheeled smoking burnout - 1125!




So I've got just over 33,000 miles on my bike and have enjoyed it thoroughly but it's started looking tired. With this economy I can't afford to buy a new bike and really, I don't think I'd want to as I love this one. But I just can't get past the fact that cleaning it doesn't do the trick anymore. I've worn through paint and I've worn through metal. I like a clean bike or at least one that has the potential to be clean and this one doesn't.

Last year I did a big trip with my girlfriend (her first) back from Colorado and then in the fall I rode the Pine Barrons 300 and crashed pretty good breaking my nose. I didn't touch the bike until a month ago.

The good part:


The not so good part:


And that is how my bike was left all winter - not even washed. It's a shame but that crash was so bad I was dizzy for well over a month and I had no interest in even seeing the bike. That and I had to move both my studio and my apartment so it wasn't until now that I decided to pull the 950 out.

I cleaned it but it was just beat. I thought about how I've always wanted to powdercoat the swingarm black and since it was still cold a few weeks ago I thought, "Why not?" and started pulling things off in a haphazard manner.



I actually regret the way that I started this as I didn't really anticipate pulling it down quite this much.



Normally I'd put every group into ziplocks and only use muffin tins for quick projects. I mentioned this to Chris, our shop whiz kid/engineer and he chirped, "It all only goes one place..." and while I got what he was saying in my head I was thinking "the garbage?"



Which brings us to "Mission Creep". In our shop Mission Creep is a serious disease which is costly, time consuming and sometimes rewarding. I'm hoping this case will be more of the last and less of the previous. The onset of Mission Creep is often recognized by the famous and damning phrase, "While it's apart..."

Here's the Mission Creep part:

Once the subframe and swingarm were off the shock was out. If the shock was out I might as well get that rebuilt but if I do the shock I should do the forks. If I pull the forks then I should have the RTT steering damper rebuilt and since that will take a week or two I'll go ahead and send the suspension off to James of Super Plush who did such an amazing job on my 525 race bike. Well, if the suspension is gone for a few weeks I should have Woody rebuild my old faded 17" rear wheel with a shiney new wider 5" rim. And if I do all that I've got time for James (Renazco) to make me a new seat since mine is now faded to brown with a lovely patina that just wouldn't look right on a clean new bike. See how this works?

Which brings us to here:



The problem here is that the frame is pretty tired looking and the paint is oxidized and if it's down to this I might just as well pull the frame and have it done as well right?

So my thought in starting this thread is to create the impetus to keep this moving. I have to keep this moving - it's getting warm and these projects are to be done in the dead of winter (what kind of idiot am I?). The problem is that seeing the bike down this far has me thinking of lots of things like repainting the whole bike or making my own custom stainless exhaust - I mean while it's apart...

sakurama screwed with this post 11-21-2013 at 07:43 PM
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Old 05-05-2009, 05:23 PM   #2
mookymoo
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Youre screwed.

You may as well do the frame.
Some new, ceramic-coated headers.


Perhaps you can buy some nice (used) plastics

And send me your motomaster brake & disc .... update to some new stockers...
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Old 05-05-2009, 05:30 PM   #3
ADVJake
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it hurts more to crash a pretty bike. yours is already broken in
I'd leave it as is, refresh & grease the bearings, give it all a check over and slap it back together. IMO!
Or go for a paintjob for something different.
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Old 05-05-2009, 05:39 PM   #4
Katoom119
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Chuck the frame in with the swingarm to be powdercoated. Seriously, you're already 95% there it'd kind of be silly not to.
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Old 05-05-2009, 05:40 PM   #5
mookymoo
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Quote:
Originally Posted by Katoom119
Chuck the frame in with the swingarm to be powdercoated. Seriously, you're already 95% there it'd kind of be silly not to.
Paint it Orange
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Old 05-05-2009, 06:39 PM   #6
Sadlsor
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Not a real hijack, but...

...did I see a Honda 400 SuperSport, dressed in red, in the background of one of your shop pix? Or was I just spacing out.... ?

I don't know whether I'd be inclined to pretty up the exterior of a 950, up there in the Bad Apple. I could see the frame re-do, but do you really want to make it any more appealing to bike-jackers?

Admittedly, I don't know your situation to speculate. I like the look of your shop, though... get that bike back to running condition ASAP. Summer's not gonna wait for you. Time keeps on ticking, ticking, ticking... into the future.
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Old 05-05-2009, 06:43 PM   #7
Qwik
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Send the frame with the Swingarm!
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Old 06-14-2009, 03:26 AM   #8
poepol
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What front mudguard are you using Sukurama?Looks carbon fibre.Good luck with the build,looks sweet already.Are you thinking about spraying the plastic too?
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Old 06-14-2009, 03:46 AM   #9
sakurama OP
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Hi Tim,

Yeah, same guy. Of course there's also stuff I never finished on that bike (like a sidestand!) and that Rickman behind has been like that for two years - brand new engine just waiting to go. So my record is hit and miss.

This project has reaffirmed how important time in the shop is for me - it's my sanity to come out to our space and just work on bikes. It makes me feel like tackling that Rickman next.

As for the pipes I like that idea but I've dented them so I have to see if that will work. I also have a bid in on a set on ebay and many projects start from winning a casual auction. If I win it I have to figure out a way to do something different with the exhaust and Flanny has me thinking about an underseat tank and K2M has done such a stunning job on his that it makes me think I could tackle it.

Paint has yet to be decided.
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Old 06-14-2009, 07:06 PM   #10
Flanny
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Quote:
Originally Posted by sakurama
If I win it I have to figure out a way to do something different with the exhaust and Flanny has me thinking about an underseat tank and K2M has done such a stunning job on his that it makes me think I could tackle it.
Feel free to PM me...I can give you the run-down on all of the pros (mostly) and cons (very few) of the low exhaust from my vantage-point...
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Old 06-26-2009, 09:41 AM   #11
Pax
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How's it going?

Just checking in to see how this is coming along?

I was sufficiently horrified by the tear down that I'm anxiously awaiting the build-up.


-Pax
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Old 06-26-2009, 12:06 PM   #12
Yellow Pig
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Great Refresh, can't wait to see how it turns out!

Get creative w/ the paintjob.

Thanks for documenting it.

Dan
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Old 06-26-2009, 01:24 PM   #13
sakurama OP
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Quote:
Originally Posted by Pax
I was sufficiently horrified by the tear down that I'm anxiously awaiting the build-up.
Yeah, me too. If I'd known it was going to be so extensive I'd have taken better notes. I got hung up by backordered swingarm bushings and steering head bearings. I could have gotten them somewhere else but didn't think of it at the time but the rest of the bearings are coming from Bearings Direct. The worst is the bearing in the sprocket carrier - $98 from KTM and $4.95 from Bearings Direct.

Anyway, I got the frame on and I'm pulling the other systems together and I'll update more next week. The goal is end of next week since I've got a week with the GF on vacation so it's extended shop time.

No paint - Revit wants me to document our trip to Labrador for the 2010 catalog so the bike can't have too crazy a paint job. That's a relief actually.

So more photos soon.
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Old 06-29-2009, 05:51 PM   #14
Douf
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Quote:
Originally Posted by sakurama

Which brings us to here:


Sorry for the hi-jack, but do you know which size adapter on the Pit-Bull stand fits the steering stem? I was looking through their catalog just a couple of days ago, but there were no KTM listings.

Thanks,

Douf
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Old 06-29-2009, 07:30 PM   #15
sakurama OP
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I'll check the dimensions when I get back out to the shop in the next day or so. I think you could just measure the inside diameter of the steering tube and use that measurement. I think the stud I have was for the TZ250 and the boxer and I just got lucky it fit the 950.

Anyway, not much to report today. I mounted tires so I'll know in a day or so if the rim sealing method of Cyborgs worked but it was certainly holding pretty good when I left. I dropped some forgotten parts at the powder coaters and sanded down the windscreen which has gotten pretty scratched. Since I'm not going to paint the whole bike I'll just paint the screen a solid gloss black.

Mostly I'm waiting on parts that are hopefully going to show up in the next few days but until then there's not a ton to do...
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